Electrically Isolated Heat Dissipating Junction Box

ABSTRACT

A junction box used for making electrical connections to a photovoltaic panel. The junction box has two chambers including a first chamber and a second chamber and a wall common to and separating both chambers. The wall may be adapted to have an electrical connection therethrough. The two lids are adapted to seal respectively the two chambers. The two lids are on opposite sides of the junction box relative to the photovoltaic panel. The two lids may be attachable using different sealing processes to a different level of hermeticity. The first chamber may be adapted to receive a circuit board for electrical power conversion. The junction box may include supports for mounting a printed circuit board in the first chamber. The second chamber is configured for electrical connection to the photovoltaic panel. A metal heat sink may be bonded inside the first chamber.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.17/097,613 filed Nov. 13, 2020, which is a continuation of U.S. patentapplication Ser. No. 16/871,117 filed May 11, 2020 (now U.S. Pat. No.10,879,840), which is a continuation of U.S. patent application Ser. No.16/524,601 filed Jul. 29, 2019 (now U.S. Pat. No. 10,686,402), which isa continuation of U.S. patent application Ser. No. 15/651,134 filed Jul.17, 2017 (now U.S. Pat. No. 10,411,644), which is a continuation of U.S.patent application Ser. No. 14/997,079 filed Jan. 15, 2016 (now U.S.Pat. No. 9,748,897), which is a continuation of Ser. No. 14/641,690filed Mar. 9, 2015 (now U.S. Pat. No. 9,748,896), which is acontinuation of U.S. patent application Ser. No. 13/901,706 filed May24, 2013 (now U.S. Pat. No. 9,006,569), which is a continuation of U.S.patent application Ser. No. 12/785,773 filed May 24, 2010 (now U.S. Pat.No. 8,476,524), which claims benefit from U.S. patent application61/180,455 filed May 22, 2009. The disclosures of the above-identifiedapplications are incorporated herein by reference for all purposes.

BACKGROUND 1. Technical Field

The present invention relates to a junction box for power sources, andspecifically to a junction box for electrically connecting to aphotovoltaic panel.

2. Description of Related Art

A photovoltaic module or photovoltaic panel is a packaged interconnectedassembly of photovoltaic cells, also known as solar cells. Since asingle photovoltaic module can only produce a limited amount of power,commercial installations include several modules or panelsinterconnected in serial and in parallel into a photovoltaic array.Electrical connections are made in series to achieve a desired outputvoltage and/or in parallel to provide a desired amount of current sourcecapability. A photovoltaic installation typically includes the array ofphotovoltaic modules, an inverter, batteries and interconnection wiring.

When part of a photovoltaic module is shaded, the shaded cells do notproduce as much current as the unshaded cells. Since photovoltaic cellsare connected in series, the same amount of current must flow throughevery serially connected cell. The unshaded cells force the shaded cellsto pass more current. The only way the shaded cells can operate at ahigher current is to operate in a region of negative voltage that is tocause a net voltage loss to the system. The current times this negativevoltage gives the negative power produced by the shaded cells. Theshaded cells dissipate power as heat and cause “hot spots”. Bypassdiodes are therefore integrated with the photovoltaic modules to avoidoverheating of cells in case of partial shading of the photovoltaicmodule.

Blocking diodes may be placed in series with cells or modules to blockreverse leakage current backwards through the modules such as to blockreverse flow of current from a battery through the module at night or toblock reverse flow down damaged modules from parallel-connected modulesduring the day.

Electronic modules may be integrated with the photovoltaic modules whichperform electrical conversion, e.g. direct current (DC) to directcurrent conversion, electrical inversion, e.g. micro-inverter, or otherfunctions such as monitoring of performance and/or protection againsttheft.

U.S. Pat. No. 7,291,036 discloses a photovoltaic connection systemincluding a connection box with for surface mounted diodes mounted on aprinted circuit board inside of the connection box. The connection boxoptionally includes a metal plate mounted inside the lid of theconnection box as a heat sink for dissipating heat from the diodes.

The term “cable gland” as used herein refers to a device used for theentry of electrical cables or cords into electrical equipment and isused to firmly secure an electrical cable entering a piece of electricalequipment.

The term “in situ” in the context of the present invention refers tobonding or attaching during manufacture, e.g. injection molding, of apart as opposed to attaching after manufacture of the part.

BRIEF SUMMARY

According to an aspect of the present invention there is provided ajunction box used for making electrical connections to a photovoltaicpanel. The junction box has two chambers including a first chamber and asecond chamber and a wall common to and separating both chambers. Thewall may be adapted to have an electrical connection therethrough. Thetwo lids are adapted to seal respectively the two chambers. The two lidsare configured to be on opposite sides of the junction box relative tothe photovoltaic panel. The two lids may be attachable using differentsealing processes. One of the lids may be adapted to seal the firstchamber and the other lid may seal the second chamber to a differentlevel of hermeticity from that of the first chamber. The first chambermay be adapted to receive a circuit board for electrical powerconversion of the power output of the photovoltaic panel. The junctionbox may include supports for mounting a printed circuit board in thefirst chamber. The second chamber is configured for electricalconnection to the photovoltaic panel. The second chamber may optionallybe configured to include diodes, e.g. bypass and/or blocking diodes. Thejunction box may have electrical connection terminals mounted inside thesecond chamber for connecting a circuit to the photovoltaic panel. Ametal heat sink may be bonded inside the first chamber. The firstchamber is adapted to receive a circuit board for electrical powerconversion, and the metal heat sink is adapted to dissipate heatgenerated by the circuit board. The heat sink is placed inside aninjection mold during manufacture of the junction box. The junction boxmay further include a pad adapted to provide thermal conduction andelectrical insulation between the circuit board and the metal heat sink.The metal heat sink may include a dovetail structure adapted to preventmutual separation of the metal heat sink from the junction box. Thedovetail structure may be hollow.

According to an aspect of the present invention there is provided ajunction box used for making electrical connections to a photovoltaicpanel. The junction box has a metal heat sink bonded in situ inside thefirst chamber. The first chamber is adapted to receive a circuit boardfor electrical power conversion, and the metal heat sink is adapted todissipate heat generated by the circuit board. The junction boxoptionally may have two chambers including a first chamber and a secondchamber and a wall common to and separating both chambers. Two lids maybe adapted to seal respectively the two chambers. The metal heat sinkmay include a dovetail structure adapted to prevent mutual separation ofthe metal heat sink from the junction box. The wall may have anelectrical connection therethrough

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects of the invention are herein described, by way of example only,with reference to the accompanying drawings, wherein:

FIGS. 1A and 1B illustrate isometric views of a junction box, accordingto an embodiment of the present invention.

FIG. 2A shows details of cross section of the junction box indicated bydotted line XX in FIG. 1A.

FIG. 2B shows details of cross section YY of the junction box indicatedby dotted line in FIG. 1A.

FIGS. 3A and 3B show isometric views of a heat sink according to anotherembodiment of the present invention.

The foregoing and/or other aspects will become apparent from thefollowing detailed description when considered in conjunction with theaccompanying drawing figures.

DETAILED DESCRIPTION

Reference will now be made in detail to embodiments of the presentinvention, examples of which are illustrated in the accompanyingdrawings, wherein like reference numerals refer to the like elementsthroughout. The embodiments are described below to explain the presentinvention by referring to the figures.

By way of introduction, diodes and/or electronic modules within junctionboxes attached to the photovoltaic modules dissipate heat. Wheninsulating junction boxes are used, heat must be dissipated mostlythrough air inside the junction box. When metallic junction boxes areused then heat may be dissipated directly through the junction box.However, the use of a metallic junction boxes may be inconvenientbecause of regulations which require accessible metallic surfaces to begrounded and extra wiring is required.

Before explaining exemplary embodiments of the invention in detail, it 1s to be understood that the invention is not limited in its applicationto the details of design and the arrangement of the components set forthin the following description or illustrated in the drawings. Theinvention is capable of other embodiments or of being practiced orcarried out in various ways. Also, it is to be understood that thephraseology and terminology employed herein is for the purpose ofdescription and should not be regarded as limiting.

Referring now to the drawings, FIG. 1A shows an isometric view 10A of ajunction box 12, according to an embodiment of the present invention.Junction box 12 is shown mounted on the back (or non-photovoltaic side)4 of a photovoltaic panel 16. Junction box 12 has cable glands 130 whichallow for termination of cables inside of junction box 12. Junction box12 has an outer casing 102 and an access into junction box 12 using alid 106.

FIG. 1B shows an isometric view of the underside of junction box 12detached from photovoltaic panel 16. The isometric view shows glands 130and two sections A and B of junction box 12. chamber A is bounded by thedimensions Z× X with chamber A covered by lid 108. Lid 108 gives accessinto chamber A of junction box 12. Chamber B is an open section which isbounded by dimensions X× Y and shows terminals 104. A bypass diode 110is connected between terminals 104. According to a feature of thepresent invention, lid 106 removed to access chamber B and lid 108 usedto access chamber A are on opposite sides of junction box 12.

FIG. 2A shows details of cross section XX of junction box 12 indicatedby dotted line in FIG. 1A, showing features of the present invention.Cross section XX shows chamber sections A and B of junction box 12mounted on non-photovoltaic side 4 of photovoltaic panel 16 with clips216. The mechanical attachment between junction box 12 and photovoltaicpanel 16 using clips 216 is such that junction box 12 is flat onphotovoltaic panel 16 and a gasket may be used to seal the open end ofchamber B.

Chamber A includes circuit board 260, thermally conductive pad 262, heatsink 264, outer casing 102 and lid 108. Circuit board 260 is preferablymounted on supports adapted to receive circuit board 260. Thermal pad262 provides electrical isolation and thermal conductivity between heatsink 264 and circuit board 260. The component side of circuit board 260is preferably in contact with thermal pad 262 so that heat created bythe components of circuit board 260 is dissipated by heat sink 264 viathermal pad 262. Radio Frequency Interference (RFI) emission fromjunction box 12 as a result of the operation of circuit board 260 isreduced by having the side of lid 108 coated in an electricallyconductive shielding 108 a. Shielding 108 a connects electrically toheat sink 264 to form a Faraday cage which suppresses RFI emission fromjunction box 12.

Lid 108 according to an aspect of the present invention is preferablymanufactured by an injection molding process. During the injectionmolding process of lid 207 a shield 108 a may be placed in situ andbonded to lid 108 during the injection molding process. Thus, when lid108 is attached to box chamber A; junction box 12 is electricallyisolated by heat sink 264 and shield 108 a. Outer casing 102 and lid 108additionally provide a non-electrically conductive isolation of heatsink 264 and shield 108 a between the backside 4 of panel 16 and theexterior of junction box 12. Lid 108 is optionally permanently and/orhermetically sealed to chamber A.

Chamber B includes terminal 104, support 214, bypass diode 110, lid 106,bus bar 212 and wall 202. Wall 202 provides physical separation betweenchambers A and B. Electrical connectivity between circuit board 260 inchamber A and electrical connector 104 in chamber B is via bus bar 212.Bus bar 212 is sealed in wall 202 in such a way as to preserve thedesired hermeticity of chamber A for example against the ingress ofwater or humidity. Both electrical connector 104 and bus bar 212 aresupported mechanically by support 214. Support 214 may also providehermetic sealing and/or electrical isolation between one end ofconnector 104 which connects to bus bar 212 and the other end ofconnector 104 which connects to connections provided by photovoltaicpanel 16. Bypass diode 110 connected to connector 104 may be locatedbetween support 214 or backside 4 of panel 16 or between support 214 andlid 106. Lid 106 gives access to chamber B whilst junction box 12 isphysically attached photovoltaic panel 16 but electrically isolated frompanel 16. A preferred mechanism of attaching lid 106 to junction box 12is to use a rubber gasket arrangement such that chamber B ishermetically sealed against for example the ingress of water/humiditythrough lid 106 into chamber B.

According to another embodiment of the present invention, junction box12 is constructed with a wall 202 that may be a double wall so thatchamber A and chamber B are mutually separable and re-attachable.Similarly, bus bar 212 is re-connectable between chamber A and chamberB. In this embodiment, a failure within the electronics of circuit board260 may be repaired by replacing chamber A with a new circuit board 260without requiring disconnection of chamber B from photovoltaic panel 16.Similarly, an electronics upgrade may be easily achieved.

Junction box 12 including casing 102, lids 108/106, heat sink 264, andthermal pad 262 are preferably adapted to comply with temperature andinsulation standard of IEC 61215 (Ed. 2) or other applicable industrystandards for use with connection to photovoltaic panels. Junction box12 and lids 108/106 may be manufactured by injection molding ofacrylonitrile butadiene styrene (ABS) thermoplastic, Polybutyleneterephthalate (PBT), Poly(p-phenylene oxide) (PPO) or a thermoset suchas epoxy resin.

FIG. 2B shows details of cross section YY of junction box 12 indicatedby dotted line in FIG. 1A, according to an embodiment of the presentinvention. Cross section YY is of chamber A mounted on backside 4 ofphotovoltaic panel 16. Cross section YY shows outer casing 102, heatsink 264 with dovetail structure 264 a, thermally conductive pad 262,circuit board 260 and lid 108 with electrical shield 108 a.

The manufacture of box chamber sections A and B of junction box 12 in apreferred embodiment of the present invention is by an injection moldingprocess. During the injection molding process heat sink 264 with orwithout dovetail structure 264 a is placed inside box chamber A and isbonded in situ to box chamber A as a result of the injection moldingprocess.

Additional strength of the bonding between heat sink 264 and box chamberA may be provided by a dovetail structure 264 a which may be an integralpart of heat sink 264. A further function of dovetail structure 264 aensures that the bonding between heat sink 264 and chamber A remainsintact when for example junction box 12 is subjected to thermal stressesas a result of electronic components operating inside chamber A, highambient heat and sunlight when junction box 12 attached to aphotovoltaic panel. Where a fastener, e.g. screw is used to fastenchamber A to heat sink 264, the lateral dimensions of dovetail structure264 a is typically increased in order to accommodate the size of thefastener. A further feature of dovetail structure 264 a is a hollowstructure within dovetail structure 264 a which allows for a deformationof dovetail structure 264 a. The deformation of dovetail structure 264 aallows for the different rates of thermal expansion of enclosure 102 andheat sink 264/dovetail structure 264 a during the curing/cooling of thebond between heat sink 264 and enclosure 102 of chamber A.

Reference is now made to FIGS. 3A and 3B which show isometric views ofheat sink 264 according to another embodiment of the present invention.Heat sink 264 has four holes 302. Holes 302 are used to attach heat sink264 into chamber A of junction box 12 using screws. The attachment ofheat sink to chamber A may come as an additional step after theinjection molding of junction box 12 or of a junction box 12 which isnot injection molded. An additional thermal pad may be placed betweenheat sink 264 and enclosure 102 to ensure good contact between heat sink264 and enclosure 102 after heat sink 264 is attached enclosure 102. Thedeformable nature of the thermal pad used to accommodate non-uniformityin surfaces of the heat sink 264 and enclosure 102 due to manufacturingtolerances of heat sink 264/enclosure 102. Alternatively a thermallyconducting glue or potting material may be placed between heat sink 264and enclosure 102.

The articles “a” “an” as used herein mean “one or more” such as “aheat-sink”, “a circuit board” have the meaning of “one or more” that is“one or more heat-sinks” or “one or more circuit boards”.

Although selected embodiments of the present invention have been shownand described, it is to be understood the present invention is notlimited to the described embodiments. Instead, it is to be appreciatedthat changes may be made to these embodiments without departing from theprinciples and spirit of the invention, the scope of which is defined bythe claims and the equivalents thereof.

1. A system comprising: at least one photovoltaic panel; a circuit boardfor electrical power conversion; and a junction box comprising a wallcommon to and physically separating a first chamber and a secondchamber, the wall comprising a first electrical connection therein,wherein the first chamber comprises: a heat sink attached therein; and arecess configured to receive the circuit board onto the heat sink,wherein the heat sink is adapted to dissipate heat generated by thecircuit board; wherein the second chamber comprises an electricalconnector providing a second electrical connection to the at least onephotovoltaic panel, and wherein the first electrical connection isconfigured to electrically connect the circuit board and the secondelectrical connection in the second chamber.
 2. The system of claim 1,wherein the junction box further comprises a bus bar sealed therein. 3.The system of claim 2, wherein the bus bar provides electricalconnectivity between the circuit board and the electrical connector. 4.The system of claim 1, wherein the wall of the junction box comprises adouble wall adapted to allow for mutual separation of the first chamberto the second chamber.
 5. The system of claim 1, wherein the wall of thejunction box comprises a double wall adapted to allow for re-attachmentof the first chamber to the second chamber.
 6. The system of claim 1,wherein replacing the first chamber of the junction box does not requiredisconnecting the second chamber of the junction box from the at leastone photovoltaic panel.
 7. The system of claim 1, wherein the firstchamber of the junction box is hermetically sealed against an ingress ofwater or humidity.
 8. The system of claim 7, wherein a bus bar is sealedin the wall of the junction box so as to preserve a level of hermeticityof the first chamber.
 9. The system of claim 1, wherein the heat sinkincludes a dovetail structure adapted to prevent mutual separation ofthe heat sink from the junction box.
 10. The system of claim 1, whereinthe first chamber of the junction box is covered by a first lid.
 11. Thesystem of claim 10, wherein the second chamber of the junction box iscovered by a second lid.
 12. The system of claim 11, wherein the secondchamber of the junction box is accessible by opening the second lid. 13.The system of claim 11, wherein the first lid and the second lid are onopposite sides of the junction box.